R0009.pdf

W68MD960487287

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83)

Prescribed by GSA

FAR (48 CFR) 53.243

Chief Joseph Dam Spillw ay Gates Lifecycle Maintenance

Please see Continuation Page for details.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 2

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 17-Jan-2017

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X W912DW-17-R-0002

X 9B. DATED (SEE ITEM 11)

29-Nov-2016

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer X is extended, is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE

RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

17-Jan-2017

CODE

USA ENGINEER DISTRICT, SEATTLE

ATTN: CECT-NWS

4735 EAST MARGINAL WAY SOUTH, BLDG. 1202

SEATTLE WA 98134-2388

W912DW 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912DW-17-R-0002

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

The purpose of Amendment nine (0009) is as follows:

Incorporate below items as indicated.

1. Specifications/Drawings – revised specifications/drawings are as follows:

35 01 41.00 10 35 20 16.46

The attached revised sections are to be replaced in their entirety. Specifications changes are generally identified, for convenience, either by strikeout for deletions, and double underlining of text for additions or a single dark line in the margin. All portions of the revised sections shall apply whether or not changes have been indicated.

2. Proposal Submittal Proposal submittal date/time is extended to 23 January 2017 at 12:30:00 p.m. LOCAL TIME. The SF1442 Solicitation, Offer and Award is revised to reflect the date extension.

If you have already submitted your proposal – and wish to make a substitution (either technical and/or price) due to this amendment, please submit a letter on company letterhead, signed by the person who signed the original SF 1442, authorizing the substitution.

NOTICE TO OFFERORS: Offerors must acknowledge receipt of this amendment by number and date on offer.

Encl:

35 01 41.00 10 (revised) 35 20 16.46 (revised) SF1442 (revised)

(End of Summary of Changes)

CJD Spillway Gate Life Cycle Maintenance 13028 Bridgeport, WA W912DW-17-R-0002

35 01 41.00 10

HOIST MACHINERY REHABILITATION

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 2015/915-1 (2002A) Accuracy Classification System - Tangential Measurement Tolerance Tables for Cylindrical Gears

ANSI/AGMA 2001 (2004D; R 2010) Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

ANSI/AGMA 2003 (2010D) Rating the Pitting Resistance and Bending Strength of Generated Straight Bevel, ZEROL Bevel, and Spiral Bevel Gear Teeth

ANSI/AGMA 6013 (2006A; R 2011) Standard for Industrial Enclosed Gear Drives

ASME INTERNATIONAL (ASME)

ASME B17.1 (1967; R 2013) Keys and Keyseats

ASTM INTERNATIONAL (ASTM)

ASTM A148/A148M (2014) Standard Specification for Steel Castings, High Strength, for Structural Purposes

ASTM A290/A290M (2016) Standard Specification for Carbon and Alloy Steel Forgings for Rings for Reduction Gears

ASTM A291/A291M (2005; R 2015) Standard Specification for Steel Forgings, Carbon and Alloy, for Pinions, Gears and Shafts for Reduction Gears

ASTM E165/E165M (2012) Standard Practice for Liquid Penetrant Examination for General Industry

ASTM E709 (2008) Standard Guide for Magnetic Particle Examination

SECTION 35 01 41.00 10 Page 1 R0009

1.2 SYSTEM DESCRIPTION

The equipment to be rehabilitated under this specification consists of 19 gate hoist units. Rehabilitate the units complete, including base supports, geared drives, shafts, bearings, wire rope, covers, guards, couplings, and other necessary items minus electrical components, brakes, motors. Wire rope is covered by Section 35 01 43 WIRE ROPE FOR GATE OPERATING DEVICES and recoating is covered by Section 09 97 02.10 PAINTING, HOIST MACHINERY. Rehabilitation of the gate machinery units shall be provided by a firm that has been normally and regularly engaged in design, assembly, and manufacture of heavy machinery over the preceding 5 years. Provide each rehabilitated (or new) gearbox and gear set with a metallic nameplate firmly attached to the cover. The nameplate shall bear the manufacturer's name, model designation, serial number, unit rating, application factor, reduction ratio's, and any other applicable information. Submit shop drawings including equipment dimensional drawings, assembly drawings, catalog cuts, and material data showing arrangement, construction details and ratings for factory built machinery;

test rig details; proposed and final shop test procedures and data sheets;

and proposed and final field operating test procedures and data sheets for approval. Provide all details of fabrication and assembly. Shop drawings lacking this information will be rejected.

Approval of the material submitted shall in no way relieve the Contractor from the responsibility of complying with the requirements of the specifications as to the suitability and quality of materials and workmanship and the adequacy of capacity, operating speed and other essential characteristics of the gate hoist drives. Submit drawings, catalogs, and design data necessary to clearly show the details of any changes proposed in conformity with the requirements of this specification. Equipment, materials, and articles of construction installed or used without such approval shall be at the risk of subsequent rejection. Furnish to the Contracting Officer for approval the names of the manufacturers of all machinery and other equipment which it contemplates incorporating into the work, together with performance capacities and other pertinent information pertaining to the equipment.

Include in the submittals the following information:

1) SPEED REDUCERS

a. Manufacturer's Name

b. Type

c. Model Number

d. Exact Ratio

e. Efficiency

f. Mechanical Rating - Durability - HP, Specify SAC

g. Mechanical Rating - Strength - HP, Specify SAT

h. Rating Calculations

i. Life Factors CL, KL

j. Reliability Factors CF, KR

k. Type of Gearing and Heat-Treatment

l. Type of Bearings

m. Minimum L-10 Bearing Life

n. Method of Lubrication

o. Size and Number of Mounting Bolts

p. Weight and Air Volume of Unit without Oil

q. Weight and Air Volume of Unit with Oil

r. Outline Dimensional Print

s. Type of Breather

SECTION 35 01 41.00 10 Page 2

t. Quantity Being Furnished

2) OPEN GEARING

a. Manufacturer's Name

b. Pinion P.D.

c. Pinion D.P.

d. Number of Teeth Pinion

e. Face Width of Pinion

f. Pinion Material

g. Heat Treatment

h. BHN of Pinion

i. Gear P.D.

j. Gear D.P.

k. Number of Teeth (Index)Gear

l. Face Width of Gear

m. Gear Material

n. Outline Dimension Print

o. Weights of Gear and Pinion

p. Quantity Being Furnished

3) MOTOR DRIVE UNIT COUPLINGS (HIGH AND LOW SPEED SHAFTS)

a. Manufacturer's Name

b. Type

c. Model Number

d. Bore Sizes and Tolerances

e. Number of Keyways

f. Keyway Sizes and Tolerance

g. Recommended Shaft Size and Tolerance

h. Recommended Key Size and Tolerance

i. Recommended Key Material

j. Keyways Filleted

k. Materials of Construction

l. Catalog Rating - Torque, HP/100 RPM

m. Service Factor Based on Catalog Rating

n. Angular Misalignment

o. Parallel Offset Misalignment

p. Axial Movement

q. Torque and HP/100 RPM Capacity of Low Speed Coupling with Anticipated

Shaft Fits

r. Type of Lubrication

s. Assembly Procedure of Hub with Shaft

t. Weight

u. Outline Dimensions Print

v. Quantity Being Furnished

4) TORQUE LIMITING COUPLINGS

a. Manufacturer's Name

b. Type

c. Model Number

d. Bore Sizes and Tolerances

e. Number of Keyways

f. Keyway Sizes and Tolerance

g. Recommended Shaft Size and Tolerance

h. Recommended Key Size and Tolerance

i. Recommended Key Material

j. Keyways Filleted

SECTION 35 01 41.00 10 Page 3

k. Materials of Construction

l. Catalog Rating - Slip Torque Range, lb-in

m. Slip Torque Setting, lb-in

n. Service Factor Based on Catalog Rating

o. Angular Misalignment

p. Parallel Offset Misalignment

q. Axial Movement

r. Torque Capacity

s. Type of Lubrication

t. Weight

u. Outline Dimensions Print

v. Quantity Being Furnished

5) SHAFT PILLOW BLOCK BEARINGS

a. Manufacturer's Name

b. Type

c. Model Number

d. Bearing Housing Material

e. Bearing Bore Diameter

f. Type of Bearing

g. Grease Grooves Included

h. Static Capacity of Bearing

i. Thrust Capacity of Bearing

j. Basic Dynamic Capacity of Bearing

k. Bearing Bore

l. Load Capacity of Bearing

m. L-10 Life of Bearing

n. Type of Seals

o. Type of Lubrication

p. Weight

q. Outline Dimensional Print

r. Quantity Being Furnished

1.2.1 Operations and Maintenance (O&M) Manuals

For specifications on the furnishing of installation, operations and maintenance instructions, see Section 01 78 23 OPERATIONS AND MAINTENANCE

MANUALS.

1.2.2 Design Criteria

a. Equipment, where modified by the Contractor and submitted for approval, shall be designed for the normal loads using factors of safety applicable to the type of service and the particular part with a minimum factor of safety of 5 based on the ultimate strength of the material. In addition, each part component, including speed reducers, shall be designed for a unit stress not in excess of 75 percent of the yield point of the material under loads resulting from the maximum torque of the motor. Both the normal loads and loads resulting from the maximum torque of the motor shall be considered as divided 75/25 between the two drums of a hoist for hoist machinery. Allowances for shock and impact will not be required. All equipment modification design calculations shall be submitted for approval.

b. All equipment will be located outside and be expected to operate between ambient temperatures from -20 to 120 degrees F.

SECTION 35 01 41.00 10 Page 4

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Field Tensioning and Operating Test Procedure

SD-02 Shop Drawings

Shop Drawings; G

SD-03 Product Data

Angle Speed Reducers; G

Parallel Shaft Reducers; G

Shaft Couplings; G

Reducer Shaft Bearings; G

Roller Bearings; G

Seals; G

Bearings Data; G

Lubricant; G

Breather; G

SD-06 Test Reports

Gear Inspection Reports; G

Post Parallel Shaft Reducer Rehabilitation Reports; G

Post Open Gear Rehabilitation Report; G

High Speed Torque Shaft Reports; G

SD-07 Certificates

Gear Inspector; G

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Delivery Time

The Contractor is hereby notified that many of the components required have long delivery times. A large percentage of the work must be accomplished during critical times. To ensure that all work required during this time period is accomplished, present to the Contracting Officer written copies of finalized purchase agreements with component

SECTION 35 01 41.00 10 Page 5 manufacturers (NOT SUPPLIERS)and work agreements with rebuilders for the components and systems noted below, within 120 calendar days after receiving notice to proceed. If any of these components/systems or other items, not listed but required, have a delivery time longer than would be provided by submission of purchase agreements 120 calendar days after receiving notice to proceed, accelerate the procurement procedures to provide delivery as needed to accomplish the work.

COMPONENTS

(1) Speed Reducers

(2) High and Low Speed Couplings

(3) Torque Limiting Couplings

(4) Bearings

(5) Gears

(6) Pinions

These purchase agreements or work agreements shall include a confirmed delivery date and point of contact at the particular manufacturer / rebuilder. The manufacturer shall be required to furnish a monthly report (a copy of which shall be submitted to the Contracting Officer on the 10th of each month) of progress on the particular component/system and any delays in the previously specified delivery date. The reporting requirements specified herein shall be included in the requirements of Section 01 32 01.00 10 PROJECT SCHEDULE.

1.4.2 Storage of Equipment

Perform delivery, handling, and storage of materials and fabricated items conforming to the requirements specified and required by the manufacturer of components. Unload materials and equipment delivered to the site in the presence of the Contracting Officer. Verify the condition and quantity of the items delivered by the Contracting Officer and acknowledge receipt and condition thereof in writing. If delivered items are damaged or a shortage is determined, notify of such in writing within 24 hours after delivery.

PART 2 PRODUCTS

2.1 ANGLE SPEED REDUCERS

Note - Information on current angle speed reducers is minimal. Contractor is required to field verify equipment to replace in-kind and provide information from manufacturers describing how it is a direct replacement or improvement and meets the intent of these specifications.

2.1.1 Angle Speed Reducers General

The double output angle speed reducers shall be replaced (Number 2 on Equipment Schedule. See Drawing M-103.) and the angle speed reducer (Number 19 on Equipment Schedule. See Drawing M-103.) shall be replaced in-kind. The speed reducers shall be replaced in kind (or improved replacement of existing), entirely self contained in an oil tight, steel housing designed to maintain shafts and bearings in accurate alignment.

The gear ratio shall be same as existing with same ratio accuracy percent. The input and output shafts shall be same diameters as existing. The double output reducer shall be designed to accommodate a 75/25 torque split between output shafts based on loads produced by the motor. Speed reducers minimum ratings shall be as existing reducers

SECTION 35 01 41.00 10 Page 6 ratings. Improved ratings are welcomed. The speed reducers shall be designed, rated and manufactured in accordance with ANSI/AGMA 6013 . The gearing shall be rated in accordance with ANSI/AGMA 2003 and ANSI/AGMA 6013 .

ANSI/AGMA 2001 is not to be used for rating and design of the components of the speed reducers. In all cases where these standards or this specification are in conflict with one another the more conservative design standard shall take precedence.

2.1.2 Reducer Housings

The reducer housing shall be heavy duty cast steel or welded steel construction and shall have dowel pins at all parting seams for accurate gear and bearing alignment. The base of the reducer shall be of sufficient thickness and width in order to reduce the stress on the mounting bolts. All surfaces shall be smooth and flat and easy to clean.

All required oil drains, fill ports, breathers, heater ports, filtering ports, and inspection covers shall be provided in the housing. A main oil drain shall be provided at as low a point as possible on the reducer housing. The main oil drain for the double output reducers shall be fitted with a 1-inch stainless steel ball valve with a WOG rating of 150 psi. The valve shall be plugged on the open end. The design of the reducer housing should minimize potential for water intrusion.

2.1.3 Gearing

All gearing shall be made from high strength alloy steel of same or greater hardness; ANSI/AGMA Quality shall be same or better than existing in accordance with AGMA 2015/915-1 , (existing quality is minimum).

2.1.4 Reducer Shafts

Shafts shall be made from high-strength alloy steel and shall be of sufficient size and as indicated to insure rigid alignment. All keyways shall have fillet radii. Keys shall be provided for all shafts. All shafts shall have standard keyways and keys in accordance with ASME B17.1 , Class II. All fabricated dimensions of the keyways and keys shall be submitted for review.

2.1.5 Reducer Shaft Bearings

The shaft bearings shall be high capacity antifriction roller bearings suitable for both radial and thrust loads. All bearings shall have a minimum L-10 bearing life of 75,000 hours based on the largest full load motor horsepower provided by the specified motor.

2.1.6 Gearbox Lubrication System

The lubrication system shall be designed to function properly at nameplate speed ratings using the specified lubricating oil. All gears and bearings shall be oil lubricated. All required oil slingers, dams, and passages shall be provided. The reducer shall be equipped with a sight gauge and dipstick in order to observe and measure the oil level.

2.1.7 Seals

Spring loaded grease-purged dual lip seals shall be provided for all shaft extensions. All seals shall be sized and designed to withstand the pressure head developed when the speed reducer is completely filled with oil (storage condition) without leaking.

SECTION 35 01 41.00 10 Page 7

2.1.8 Breather

All reducers shall be provided with a hygroscopic breather with threaded fittings for installation to prevent problems caused by moisture and particulate matter contamination in the reducer when it breathes in and out due to temperature fluctuations. The breather shall filter particles down to 12 microns in size. The hygroscopic agent shall change color signifying when the unit requires replacement, i.e., when the desiccant is saturated with moisture. There shall be no air flow stoppage through the breather under freezing conditions.

2.2 PARALLEL SHAFT SPEED REDUCERS

2.2.1 Parallel Shaft Reducers General

The Western Gear parallel shaft triple reduction speed reducers shall be rehabilitated (Number 3 on equipment schedule See Drawing M-103). Each reducer shall be cleaned, torn down, inspected, and at a minimum have bearings and seals replaced. Gear box and component inspection and rehabilitation shall be performed by a gear manufacturer that has been inspecting, repairing, manufacturing, and engineering gears for 20 years or more. The manufacturer shall have capabilities to repair and rebuild parallel shaft reducers of this size.

2.2.1.1 Inspection

Magnetic particle examination shall be performed in accordance with the requirements set forth in ASTM E709 and ASTM E165/E165M , respectively.

Gear Inspection Reports shall contain inspection results, gears inspected, name of inspector, photographs of flaws and problems, photos of each gear, repair reccomendations for gear sets, housing inspection results, and reccomended housing repairs.

a. Gear Teeth and shaft inspection shall be magnetic particle.

b. Photograph all flaws, cracks, and problems. The results of the nondestructive examination along with the repair procedure shall be submitted for approval prior to gear repair or remachining (grinding or cutting), or replacement.

Post parallel shaft reducer rehabilitation reports shall be submitted.

Post Parallel Shaft Reducer Rehabilitation Reports shall have results of gear mesh , backlash, alignement, and contact patterns for each gear box.

Reducer in report shall be identified by new tag put on each box.

2.2.2 Replacement Gearing

All gearing shall be made from high strength alloy steel of same or greater hardness as defined by appropriate reference drawings; ANSI/AGMA Quality shall be same or better than existing in accordance with AGMA 2015/915-1 , (existing quality is minimum).

2.2.3 Reducer Housings

The reducer housing shall be inspected. The results of the examination along with the repair procedure shall be submitted for approval prior to any reducer housing repair.

SECTION 35 01 41.00 10 Page 8

2.2.4 Replacement Reducer Shafts

Shafts shall be made from high-strength alloy steel and shall be of sufficient size to insure rigid alignment. All keyways shall have fillet radii. Keys shall be provided for all shafts. All shafts shall have standard keyways and keys in accordance with ASME B17.1 , Class II. All fabricated dimensions of the keyways and keys shall be submitted for review.

2.2.5 Reducer Shaft Bearings

The shaft bearings shall be high capacity antifriction roller bearings suitable for both radial and thrust loads. All bearings shall have a minimum L-10 bearing life of 75,000 hours based on the largest full load motor horsepower provided by the specified motor. Submit bearings data for USACE records.

2.2.6 Seals

Provide spring loaded grease-purged dual lip seals for all shaft extensions. All seals shall be sized and designed to withstand the pressure head developed when the speed reducer is completely filled with oil (storage condition) without leaking. Submit seals data for USACE records.

2.2.7 Breather

Reinstall all reducers with a hygroscopic breather with threaded fittings for installation to prevent problems caused by moisture and particulate matter contamination in the reducer when it breathes in and out due to temperature fluctuations. The breather shall filter particles down to 3 microns in size. The hygroscopic agent shall change color signifying when the unit requires replacement, i.e., when the desiccant is saturated with moisture. There shall be no air flow stoppage through the breather under freezing conditions. Submit breather data for USACE records.

2.3 BEARINGS

2.3.1 General Requirements

Replace all fixed and floating roller bearings (Numbers 15, 15A, 16, 16A, and 17 on Equipment Schedule, see Drawing M-103). The minimum L-10 bearing life shall be 75,000 hours based on the full load motor horsepower. Service and installation factors shall be in accordance with the bearing manufacturer's recommendations. All bearings shall be equipped with labyrinth seals to exclude foreign matter and retain lubrication without leakage under both static and dynamic operating conditions. It is expected that housings are in good conditions and most will remain. Bearings will be replaced in housings according to manufacturers reccomendations and requirements. Submit bearings data for USACE records. Field verify all bearings before ordering and replacing.

2.4 SHAFT COUPLINGS

2.4.1 General

Replace all couplings in kind on all shafts. Couplings shall be of sufficient capacity to develop the full strength of the shafting which

SECTION 35 01 41.00 10 Page 9 they connect and shall be pressed and keyed thereon. The key fit shall be in accordance with ASME B17.1 , Class II. The fabricated dimensions of the key fit shall be submitted for review. Couplings shall be equipped with lube plugs and enclosed and sealed with an elastomeric O-ring to retain the lubricant and shall be oiltight under both static and dynamic operating conditions. Bolts shall be SAE grade 8. Misalignment for gear couplings shall be minimized by not exceeding the manufacturer's recommendations for installation limits pertaining to gap-hub separation, angular alignment, and parallel offset alignment measurements. New couplings shall meet or exceed ratings and quality of existing couplngs.

Submit couplings data and state how and why new couplings meet or exceed ratings and quality of existing couplings.

2.5 LUBRICATION

Provide lubricating oil for speed reducers shall as recommended by the gearbox manufacturer / rebuilder for environment and operating conditions. It shall have good resistance to foaming under normal operating conditions and shall be non-corrosive to speed reducer components. The oil shall be suitable for infrequent intermittent duty operation of the speed reducers with an ambient temperature range from -10 degrees F to 110 degrees F. Submit lubricant data with explanation from manufacturer stating how it is best for the application. Drain and fill plugs for speed reducers shall be located so as to be readily accessible on the completed units and shall be provided with extension piping where required. Couplings and bearings shall be grease lubricated in accordance with the manufacturer's instructions.

Lubricating Grease for open gearing shall be same as currently in use by Chief Joseph Dam.

Submit lubricant data for USACE records. If there is a recommended change in grease lubricant from that currently used by CJD staff, submit information on the affects of mixing lubricants. If mixing of the current and recommended lubricants is problematic, a different lubricant shall be proposed.

2.6 OPEN GEARING

2.6.1 General

Clean and inspect the existing intermediate and final gears (Numbers 4,5,6 & 7 in Equipment Schedule, see Drawing M-103). Inspections shall determine if gears are adequate. If necessary, the gears shall be re-ground and/or new gears shall be re-cut and installed. Re-cut gears, when meshed with the new pinion or pinions shall have a backlash of 0.025-inch to 0.035-inch to final drive. After reinstallation the alignment shall be within 0.001 in per inch width.

2.6.2 Inspection - Nondestructive Examination and Inspector

Perform magnetic particle and dye penetrant examination in accordance with the requirements set forth in ASTM E709 and ASTM E165/E165M , respectively.

Gear Inspector shall have minimum of 5 years documented experience and be approved by a gear manufacturer that has been producing and repairing gears for more than 20 years.

Gear Inspection Reports shall contain inspection results, location of

SECTION 35 01 41.00 10 Page 10 gears inspected, results, name of inspector, photographs of relevant indications, overall photos of each gear, shaft, and repair reccomendations for gear sets.

a. Gear teeth (magnetic particle or dye penetrant). Only indications with major dimensions greater than 1/32-inch shall be considered relevant.

The following relevant indications shall be unacceptable: any linear indications greater than 3/32-inch (a linear indication is defined as one whose length is three times its width); rounded indications with dimensions greater than 3/32-inch; four or more relevant indications in a line separated by 1/32-inch or less, edge to edge; and ten or more relevant indications in any 6 square inches of surface with the major dimension of this area not to exceed 6 inches when taken in the most unfavorable orientation relative to the indications being evaluated.

b. Gear spokes, hub, and shafts (dye penetrant). Only indications with major dimensions greater than 3/16-inch shall be considered relevant.

The following relevant indications shall be unacceptable: any linear indications greater than 3/16-inch (a linear indication is defined as one whose length is three times its width); rounded indications with dimensions greater than 3/16-inch; four or more relevant indications in a line separated by 1/8-inch or less, edge to edge; and ten or more relevant indications in any 6 square inches of surface with the major dimension of this area not to exceed 6 inches when taken in the most unfavorable orientation relative to the indications being evaluated.

Inspect shafts for straightness, overstressing, and other potential problems.

c. Map and photograph all relevant indications. The results of the nondestructive examination along with the repair procedure shall be submitted for approval prior to gear repair or remachining (grinding or cutting). Inherent indications resulting from the original fabrication of the gears shall be omitted from repair at the discretion of the Government.

After replacement of bearings and all other work on open gear sets, inspect and report on gear mesh, contact patterns,and backlash. Provide a Post Open Gear Rehabilitation Report. The report shall contain photos, inspection results, and location of gears, and notable items found.

2.7 OPEN GEARING REPLACEMENT GEARS

The pinion gears shall be of the spur type and shall be cut from solid steel conforming to ASTM A291/A291M . The minimum tensile strength and Brinell Hardness shall be at least what is required per Table 2 of ASTM A291/A291M . The bull gears shall be of spur type and are of fabricated or cast construction cast steel conforming to ASTM A148/A148M (cross referenced from QQ-S-681, CL105-85) and ASTM A290/A290M accordingly .

Gear grade and specification shall meet or exceed that as defined on supplied reference drawings. Submit certified material test results for the gears and shafts.

2.7.1 CONTRACTOR DESIGNED GEARING

Contractor designed gearing must be engineered, designed, and manufactured by a reputable gear manufacturer who has prior experience in designing and supplying the specified size gearing. Submit the manufacturer's required calculations and shop drawings for the design and fabrication of the

SECTION 35 01 41.00 10 Page 11 identified gearing prior to the start of shop fabrication. Durability rating of gears must be as determined by ANSI/AGMA 2001 and based on a service factor of 1.

2.8 HOIST DRUMS

For specific requirements see Section 35 01 43 WIRE ROPE FOR GATE

OPERATING DEVICES.

2.9 WIRE ROPE ASSEMBLY

For specifications on the wire rope and terminations see Section 35 01 43

WIRE ROPE FOR GATE OPERATING DEVICES.

2.10 HIGH SPEED TORQUE SHAFTS

All high speed torque shafts shall be cleaned and inspected for flaws and overstressing. Welds shall be examined by magnetic particle or dye penetrant. Examination shall be performed in accordance with the requirements set forth in ASTM E709 and ASTM E165/E165M , respectively.

All shafts shall be balanced for the operating speed. Balancing shall be to ISO 1940-1 G16. Balancing facility shall have been in operation balancing drivelines or industrial shafts for a minimum of 5 years.

Shafts shall be inspected for straightness and adjusted if out of tolerance. Straightness tolerance shall be 0.001 in/ft. Straighten before balancing all shafts. Produce inspection reports for high speed torque shaft including balancing and straightening reports. Indicate spillway location for each shaft on the High Speed Torque Shaft Reports.

The results of the nondestructive examination along with the repair procedure shall be submitted for approval prior to repairing shafts if necessary.

2.11 GUARDS AND COVERS

Safety guards or covers removed for rehabilitation work shall be replaced as necessary to protect the operators from accidental contact with moving parts. Openings in guards and covers shall match existing orientation or be modified as necessary to provide access to parts requiring lubrication or regular maintenance.

2.12 STRUCTURAL BASES AND SUPPORTS

See Section 09 97 02.10 PAINTING - HOIST MACHINERY for rehabilitation requirements. Note requirement for a hold point to allow a structural inspection by USACE after bases are cleaned.

2.13 PAINTING

All exposed ferrous surfaces shall be painted as required by the manufacturer or Section 09 97 02.10 PAINTING - HOIST MACHINERY and touched up after installation. Painting of nonferrous metals and corrosion resisting steel will not be required unless otherwise specified.

SECTION 35 01 41.00 10 Page 12

2.14 ASSEMBLY AND TESTS

2.14.1 General

Each machinery unit consisting of the motor, brake, reducer, cable drums, open gear sets, high speed torque shafts, couplings, bearings, and parallel shaft reducer shall be completely assembled on its structural steel base on the spillway and tested in the presence of a representative of the Contracting Officer before wire ropes are installed. Notify the Contracting Officer at least 5 calendar days before testing of each machinery unit. This notification shall include information on how many units will be tested and the estimated time frame involved with each test. The witnessing of a particular test may be waived by the Contracting Officer, however, the approved test procedures, notification, and documentation shall still be performed as required by these specifications. Once informed that Government personnel will witness the test(s), notify the Contracting Officer that a particular test is scheduled as planned a minimum of 24 hours prior to the test.

Perform all necessary preparations and preliminary testing prior to issuing the 24 hour notification. Testing shall commence upon the arrival of Government personnel at the scheduled location and time. Details of the test rig and its location shall be submitted for evaluation and approval of the Contracting Officer. The submittal shall address aspects including how the work will be protected, how the test measurements will be made, and how test results can be verified. All bearing surfaces and lubrication lineinteriors shall be cleaned and reducer bearings, couplings, and gears properly lubricated before tests are begun. All speed reducers shall be properly filled with the specified lubricating oil. The transfer of lubricating oil from one unit to another will not be allowed. The motors, brakes, and controls shall be electrically connected and operated at rated voltage.

2.14.2 Test Procedure

Submit the test procedure, with a blank test results data sheet, to the Contracting Officer for review and approval prior to the commencement of any tests. The test procedure applies to all units. Each piece of equipment shall be inspected for smooth operation and proper alignment and all necessary clearances checked to ensure binding or excessive heat does not occur in any moving part. During the test, readings of motor current, RPM, voltage, temperature and bearing temperature shall be provided to the Contracting Officer. The test shall be stopped immediately if there is any undue noise, vibration, or heat developed in any of the bearings.

After correction of alignment and/or all other causes for the interruption of the test, the unit shall be re-inspected and testing shall resume when permitted by the Contracting Officer. Final operating test results for each unit shall be submitted to the Contracting Officer.

PART 3 EXECUTION

3.1 FIELD ERECTION AND TESTS

Field erection and field tests will be made by and at the expense of the Contractor under the general supervision of a Mechanical Engineer to be furnished by the Contractor under the provisions of the Paragraph MECHANICAL ENGINEER. Submit the Field Tensioning and Operating Test Procedure, with a blank test results data sheet for review and approval prior to the commencement of any field tests.

SECTION 35 01 41.00 10 Page 13

Accurately align and connect the wire rope assemblies to each end of the gate. The wire rope field tensioning procedure shall be based on the following steps. Upon connection of the wire rope to the gate, equalize the tension in the cables by the use of a deflection-type cable tension indicator mounted to each cable. After adjustment of a set of wire ropes, the gate shall be raised one foot above the sill and the cables checked for uniform tension. Equal tensioning will be considered achieved when the tension of the cables is within 5 percent of the mean tension per rope for that set of wire ropes. The load supporting each side of the gate shall not be less than 48 percent nor more than 52 percent of the total load. Adjustments shall be repeated until the wire ropes have been correctly tensioned.

After the units have been installed and final alignments are made and the field tensioning tests are complete, each complete unit will be operated and the gate fully raised and lowered a sufficient number of cycles (but no less than 3), to demonstrate to the Contracting Officer that the requirements of the specifications have been met and that the performance of the equipment is satisfactory for the purpose intended. The cable drums shall be inspected to ensure proper reeving of the cable. During the test, readings of motor RPM, current, voltage, temperature and bearing temperature shall be provided to the Contracting Officer as data to enable estimation of the motor horsepower developed. The test shall be stopped immediately if there is any undue noise, vibration, or heat developed in any of the bearings. After correction of alignment and/or all other causes for the interruption of the test, the unit shall be re-inspected and testing shall resume when permitted by the Contracting Officer. Final field tensioning and operating test results for each unit shall be submitted to the Contracting Officer.

3.2 MECHANICAL ENGINEER

a. Furnish the services of a competent mechanical engineer to supervise and direct the re-installation of this equipment. The mechanical engineer shall be present for all inspections and tests.

b. The mechanical engineer has sole responsibility for the equipment meeting all the requirements of these specifications.

c. The mechanical engineer shall verify the fit and alignment of mating components prior to installing in the field and be present during final connection and field testing for contract compliance. The mechanical engineer shall keep records of all measurements taken during installation and testing.

3.3 FIELD TRAINING

Provide field training for maintenance and operating staff after each system is functionally complete, but prior to final acceptance. The training shall be given for a period of 2 hours. The training shall cover all pieces of equipment and shall include items contained in the operation and maintenance manuals.

3.4 ACCEPTANCE

Upon successful completion of the field tests, the gate hoist machinery and accessory items and equipment will be examined by the Contracting Officer, and, if found to comply with the contract, they will be accepted

SECTION 35 01 41.00 10 Page 14 and the Contractor will be furnished written notice of such acceptance.

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SECTION 35 20 16.46

SEALS REPLACEMENT

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM A167 (1999; R 2009) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A176 (1999; R 2009) Standard Specification for Stainless and Heat-Resisting Chromium Steel Plate, Sheet, and Strip

ASTM A240/A240M (2012a) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A276 (2010) Standard Specification for Stainless Steel Bars and Shapes

ASTM D2240 (2005; R 2010) Standard Test Method for Rubber Property - Durometer Hardness

ASTM D395 (2003; R 2008) Standard Test Methods for Rubber Property - Compression Set

ASTM D412 (2006a; E 2008; R 2008) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D413 (1998; R 2007) Rubber Property - Adhesion to Flexible Substrate

ASTM D471 (2012a) Standard Test Method for Rubber Property - Effect of Liquids

ASTM D572 (2004; R 2010) Rubber Deterioration by Heat and Oxygen

ASTM F593 (2002e1) Stainless Steel Bolts, Hex Cap Screws, and Studs

ASTM F594 (2009e1) Standard Specification for Stainless Steel Nuts

SECTION 35 20 16.46 Page 1

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Detail Drawings; G

SD-03 Product Data

Materials

SD-04 Samples

Materials; G

Manufactured Units; G

Fabrications; G

SD-06 Test Reports

Tests, Inspections, and Verifications

1.3 QUALITY ASSURANCE

1.3.1 Manufactured Units and Fabricated Items

Samples of manufactured units and shop fabricated shall be full-size and complete as required for installation in the work. Approved samples may be installed in the work provided each sample is identified and its location recorded.

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 General

Perform delivery, handling, and storage of materials and fabricated items in conformance with the requirements specified herein. Protective wrappings and coverings shall not be removed until immediately prior to use in the work.

1.4.2 Rubber Seals

Store rubber seals in a place which permits free circulation of air, maintains a temperature of 70 degrees F or less, and prevents the rubber from being exposed to the direct rays of the sun. Keep rubber seals free of oils, grease, and other materials which would deteriorate the rubber.

Rubber seals shall not be distorted during handling.

PART 2 PRODUCTS

2.1 MATERIALS

System of identification which shows the disposition of specific lots of

SECTION 35 20 16.46 Page 2 approved materials and fabricated items in the work, before completion of the contract. Provide materials orders, materials lists, and materials shipping bills.

2.1.1 Metals

Structural steel, steel forgings, steel castings, stainless steel, bronze, aluminum-bronze, and other metal materials used for fabrication and/or installation shall conform to the requirements shown on the drawings and specified herein.

2.1.1.1 Stainless Steel Bars and Shapes

ASTM A276, UNS S 30400, Condition A, hot-finished or cold-finished, Class C.

2.1.1.2 Stainless Steel Plate, Sheet, and Strip

ASTM A167, UNS S 30400; ASTM A176, UNS S 40500 or U NS S 41008; and ASTM A240/A240M , UNS S 30400,. Plate finish shall be hot-rolled, annealed or heat-treated, and blast-cleaned or pickled. Sheet and strip finish shall be No. 1.

2.1.2 Gaskets for Seal Assemblies

Rubber gasket sheets for seal assemblies shall have nominal Shore A durometer value of 80 with dimensions as shown on the reference drawings.

2.1.3 Rubber Seals

2.1.3.1 General

Rubber seals shall be fluoro-carbon (Teflon) clad rubber seals of the mold type only, shall be compounded of natural rubber, synthetic polyisoprene, or a blend of both, and shall contain reinforcing carbon black, zinc oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers.

Physical characteristics of the seals shall meet the following requirements:

PHYSICAL TEST TEST VALUE TEST METHOD SPECIFICATION

Tensile Strength 2500 psi (min.) ASTM D412

Elongation at Break 450 percent (min.) ASTM D412

300 percent Modulus 900 psi (min.) ASTM D412

Durometer Hardness (Shore Type A)

60 to 70 ASTM D2240

*Water Absorption 5 percent by weight (max.) ASTM D471

Compression Set 30 percent (max.) ASTM D395

Tensile Strength (after aging 48 hrs)

80 percent tensile strength (min.)

ASTM D572

The "Water Absorption" test shall be performed with distilled water. The

SECTION 35 20 16.46 Page 3 washed specimen shall be blotted dry with filter paper or other absorbent material and suspended by means of small glass rods in the oven at a temperature of 70 degrees C plus or minus 2 degrees C for 22 hours plus or minus 1/4 hour. The specimen shall be removed, allowed to cool to room temperature in air, and weighed. The weight shall be recorded to the nearest 1 mg as W1 (W1 is defined in ASTM D471). The immersion temperature shall be 70 degrees C plus or minus 1 degree C and the duration of immersion shall be 166 hours.

2.1.3.2 Fabrication

Rubber seals shall have a fluoro-carbon film vulcanized and bonded to the sealing surface of the bulb. The film shall be 0.030 inch thick Huntington Abrasion Resistant fluoro-carbon Film No. 4508, or equal, and shall have the following physical properties:

Tensile strength 2,000 psi (min.)

Elongation 250 percent (min.)

The outside surface of the bonded film shall be flush with the surface of the rubber seal and shall be free of adhering or bonded rubber. Strips and corner seals shall be molded in lengths suitable for obtaining the finish lengths shown on the drawings and with sufficient excess length to provide test specimens for testing the adequacy of the adhesion bond between the film and bulb of the seal. At one end of each strip or corner seal to be tested, the fluoro-carbon film shall be masked during bonding to prevent a bond for a length sufficient to hold the film securely during testing.

2.2 MANUFACTURED UNITS

Bolts, nuts, washers, screws and other manufactured units shall conform with the requirements shown on the drawings and specified herein.

2.2.1 Bolts, Screws, Nuts, and Washers

Bolts, screws, nuts, and washers shall conform to ASTM F593 and ASTM F594, UNS s 30400. Bolts 1/2-inch and larger shall have hexagon heads. The finished shank of bolts shall be long enough to provide full bearing.

Washers for use with bolts shall conform to the requirements specified in the applicable specification for bolts.

2.3 FABRICATION

2.3.1 Detail Drawings

Submit detail drawings, including fabrication drawings, shop assembly drawings, delivery drawings, and field installation drawings, conforming to the requirements specified herein.

2.3.1.1 Fabrication Drawings

Show on the fabrication drawings complete details of materials, tolerances, connections, finished surfaces, machined surface finishes, and proposed welding sequences which clearly differentiate shop welds and field welds.

SECTION 35 20 16.46 Page 4

2.3.1.2 Shop Assembly Drawings

Provide on the shop assembly drawings details for connecting the adjoining fabricated components in the shop to assure satisfactory field installation.

2.3.1.3 Delivery Drawings

Provide on the delivery drawings descriptions of methods of delivering components to the site, including details for supporting fabricated components during shipping to prevent distortion or other damages.

2.3.1.4 Field Installation Drawings

Provide on the field installation drawings a detailed description of the field installation procedures. The description shall include the location and method of support of installation and handling equipment; provisions to be taken to protect concrete, spillway gates and other work during installation; method of maintaining components in correct alignment; plan for prestretching seals.

2.3.2 Fabrication

Fabrication shall conform with the requirements shown on the drawings and specified herein. Components shall be shop-fabricated of the materials specified and shown on the drawings. Dimensional tolerances shall be as specified and shown on the drawings. Splices shall occur only where shown on the drawings or approved by the Contracting Officer. Pin holes shall be bored in components after welding, straightening, stress-relieving, and threading operations are completed. Brackets, eye bar sections, and other components requiring straightening shall be straightened by methods which will not damage the material. Bronze bushings shall be press-fitted with supporting components. Bolt connections, lugs, clips, or other pick-up assembly devices shall be provided for components as shown and required for proper assembly and installation. Provisions shall be made for the installation of appurtenances as required.

2.3.3 Bolted Connections

Bolted connections shall conform with the requirements specified on the drawings and by the seal manufacturer.

2.3.4 Machine Work

Machine work shall conform with the requirements specified herein and on the drawings.

2.3.5 Miscellaneous Provisions

Miscellaneous provisions for fabrication shall conform with the requirements specified herein and general best practices of the industry.

2.3.6 Fabrications

Submit samples for approval prior to use of the represented materials or items in the work. Samples of standard and shop fabricated items shall be full size and complete as required for installation in the work. Approved samples may be installed in the work provided each sample is clearly identified and its location recorded.

SECTION 35 20 16.46 Page 5

2.3.6.1 Seal Assemblies

Seal assemblies shall consist of rubber seals, retainer and spacer bars, and fasteners. Rubber seals shall be continuous over the full length.

Seals shall be accurately fitted and drilled for proper installation.

Bolt holes shall be drilled in the rubber seals by using prepared templates or the retainer bars as templates. Splices in seals shall be fully molded, develop a minimum tensile strength of 50 percent of the unspliced seal, and occur only at locations shown on the drawings.